U.S. patent number 10,780,338 [Application Number 15/655,535] was granted by the patent office on 2020-09-22 for system and methods for designing and manufacturing bespoke protective sports equipment.
This patent grant is currently assigned to Riddell, Inc.. The grantee listed for this patent is Riddell, Inc.. Invention is credited to Vittorio Bologna, Murphy Gillogly, Thad M. Ide, Andrew Tryner.
![](/patent/grant/10780338/US10780338-20200922-D00000.png)
![](/patent/grant/10780338/US10780338-20200922-D00001.png)
![](/patent/grant/10780338/US10780338-20200922-D00002.png)
![](/patent/grant/10780338/US10780338-20200922-D00003.png)
![](/patent/grant/10780338/US10780338-20200922-D00004.png)
![](/patent/grant/10780338/US10780338-20200922-D00005.png)
![](/patent/grant/10780338/US10780338-20200922-D00006.png)
![](/patent/grant/10780338/US10780338-20200922-D00007.png)
![](/patent/grant/10780338/US10780338-20200922-D00008.png)
![](/patent/grant/10780338/US10780338-20200922-D00009.png)
![](/patent/grant/10780338/US10780338-20200922-D00010.png)
View All Diagrams
United States Patent |
10,780,338 |
Bologna , et al. |
September 22, 2020 |
System and methods for designing and manufacturing bespoke
protective sports equipment
Abstract
A bespoke protective sports equipment to be worn by a player
engaged in a sporting activity is provided. The bespoke sports
equipment system includes methods for acquiring, storing and
processing a player's unique data, namely the anatomical features
of the body part against which the bespoke equipment is worn. The
systems also includes methods of using the player's unique data to
manufacture the bespoke protective equipment with a custom formed
internal padding assembly that substantially corresponds to the
player's unique data. The system and method allows for the design
and manufacture of bespoke protective sports equipment that is
purposely designed and manufactured to match the anatomical
specifications of the player's body part.
Inventors: |
Bologna; Vittorio (Des Plaines,
IL), Gillogly; Murphy (Des Plaines, IL), Tryner;
Andrew (Des Plaines, IL), Ide; Thad M. (Des Plaines,
IL) |
Applicant: |
Name |
City |
State |
Country |
Type |
Riddell, Inc. |
Des Plaines |
IL |
US |
|
|
Assignee: |
Riddell, Inc. (Des Plaines,
IL)
|
Family
ID: |
1000002805798 |
Appl.
No.: |
15/655,535 |
Filed: |
July 20, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
62364629 |
Jul 20, 2016 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A42C
2/007 (20130101); A63B 71/10 (20130101); A42B
3/127 (20130101); A63B 71/1225 (20130101); A42B
3/0406 (20130101); A42B 3/08 (20130101); A42B
3/20 (20130101); A42B 3/283 (20130101); G06F
30/00 (20200101); G06F 2119/18 (20200101); A63B
2071/125 (20130101); A63B 2071/1233 (20130101); A63B
2071/1208 (20130101); A63B 2071/1241 (20130101); A63B
2071/1258 (20130101) |
Current International
Class: |
A42B
3/12 (20060101); A42B 3/28 (20060101); A63B
71/12 (20060101); G06F 30/00 (20200101); A42C
2/00 (20060101); A63B 71/10 (20060101); A41D
13/05 (20060101); A42B 3/20 (20060101); A42B
3/04 (20060101); A42B 3/08 (20060101); A42B
3/06 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
1735921 |
|
Feb 2006 |
|
CN |
|
101204904 |
|
Jun 2008 |
|
CN |
|
2490894 |
|
Nov 2012 |
|
GB |
|
200045119 |
|
Feb 2000 |
|
JP |
|
2000245888 |
|
Sep 2000 |
|
JP |
|
2308763 |
|
Oct 2007 |
|
RU |
|
2005129896 |
|
Oct 2007 |
|
RU |
|
2005060392 |
|
Oct 2005 |
|
WO |
|
17171694 |
|
Oct 2017 |
|
WO |
|
Other References
Walmink et al., Interaction opportunities around helmet design, 4
pages (Year: 2014). cited by examiner .
International Search Report and Written Opinion issued in
PCT/US2017/043132 dated Sep. 28, 2017 (10 pages). cited by
applicant .
International Search Report and Written Opinion issued in
PCT/US14/11877 dated Apr. 24, 2014 (12 pages). cited by
applicant.
|
Primary Examiner: Dao; Thuy
Attorney, Agent or Firm: Barnes & Thornburg LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to, under 35 U.S.C. .sctn. 119,
U.S. Provisional Application No. 62/364,629 filed on Jul. 20, 2016,
the entire content of which is hereby incorporated by reference in
its entirety for all purposes.
Claims
The invention claimed is:
1. A method for manufacturing a bespoke protective sports helmet to
be worn by a player while playing a sports activity, comprising:
performing a scan of a player's head with the scanning apparatus;
aligning the scan relative to a reference surface, wherein said
reference surface is associated with a selected helmet size within
the three-dimensional software; comparing the aligned scan of the
player's head against the reference surface of the selected helmet
size within the three-dimensional software to confirm that the scan
does not penetrate the reference surface; inwardly adjusting the
aligned scan of the player's head by a predetermined amount within
the three-dimensional software to create a modified scan of the
player's head; forming a bespoke pad based on the modified scan of
the player's head; and installing the bespoke pad into a protective
sports helmet shell.
2. The method for manufacturing the bespoke protective sports
helmet according to claim 1, wherein the step of inwardly adjusting
the aligned scan of the player's head results in an increase of the
thickness of the bespoke pad.
3. The method for manufacturing the bespoke protective sports
helmet according to claim 1, wherein the step of aligning the scan
relative to the reference surface includes adjusting the scan based
on the player's playing position or playing level.
4. The method for manufacturing the bespoke protective sports
helmet according to claim 3, wherein adjusting the scan based on
the player's playing position or playing level includes moving the
scan either forward or backward in comparison to the location of
the aligned scan based on the player's playing position or playing
level.
5. The method for manufacturing the bespoke protective sports
helmet according to claim 1, wherein the step of aligning the scan
relative to the reference surface includes adjusting the scan based
on data collected from the player's on-field wearable monitoring
system.
6. The method for manufacturing the bespoke protective sports
helmet according to claim 5, wherein adjusting the scan based on
data collected from the player's on-field wearable monitoring
system includes moving the scan either forward or backward in
comparison to the location of the aligned scan based on data
collected from the player's on-field wearable monitoring
system.
7. The method for manufacturing the bespoke protective sports
helmet according to claim 1, wherein the step of capturing a scan
of a player's head with the scanning apparatus includes: placing a
scanning hood on the player's head; and acquire images of portions
of the player's head and portions of a scanning hood overlying the
player's head.
8. The method for manufacturing the bespoke protective sports
helmet according to claim 7, wherein the step of capturing a scan
of a player's head with the scanning apparatus includes stitching
together images of portions of the player's head and portions of a
scanning hood overlying the player's head to generate a
three-dimensional representation of the player's head.
9. The method for manufacturing the bespoke protective sports
helmet according to claim 7, wherein the step of capturing a scan
of a player's head with the scanning apparatus further includes:
selecting a scanning helmet size; placing a scanning helmet of the
selected scanning helmet size on the player's head over the
scanning hood; capturing a helmet scan of the player wearing the
scanning hood and scanning helmet with a scanning apparatus; and
removing the scanning helmet from the player's head and capturing a
hood scan with the scanning apparatus while the player is wearing
the scanning hood.
10. The method for manufacturing the bespoke protective sports
helmet according to claim 1, wherein the step of forming a bespoke
pad based on the modified scan of the player's head includes
selecting a compression deflection rating of the at least one pad
member is selected based on at least one of the following factors:
i) player's impact history, ii) player's skill level, or iii)
player's position.
11. The method for manufacturing the bespoke protective sports
helmet according to claim 1, further comprising the step of adding
an identification device to the bespoke pad.
12. A method for manufacturing a bespoke protective sports helmet
to be worn by a player while playing a sports activity, comprising:
capturing a scan of a player's head with the scanning apparatus;
aligning the scan relative to a reference surface that is
associated with a selected helmet size within the three-dimensional
software; modifying the aligned scan of the player's head based on
the player's playing position or playing level to create a modified
scan of the player's head that includes moving the aligned scan of
the player's head either towards a front region or a rear region of
the helmet; forming a bespoke pad based on the modified scan of the
player's head; and installing the bespoke pad into a protective
sports helmet shell.
13. The method for manufacturing the bespoke protective sports
helmet according to claim 12, further comprising the step of
inwardly adjusting the aligned scan of the player's head by a
predetermined amount after the scan is confirmed not to penetrate
the reference surface.
14. The method for manufacturing the bespoke protective sports
helmet according to claim 13, wherein the step of inwardly
adjusting the aligned scan of the player's head results in an
increase of the thickness of the bespoke pad that is installed in
the protective sports helmet.
15. The method for manufacturing the bespoke protective sports
helmet according to claim 12, further comprising the step of
comparing the modification of the aligned scan of the player's head
against a reference surface of the selected helmet size within the
three-dimensional software to confirm that the scan does not
penetrate the reference surface.
16. The method for manufacturing the bespoke protective sports
helmet according to claim 12, wherein the step of capturing a scan
of a player's head with the scanning apparatus includes: placing a
scanning hood on the player's head; and acquire images of portions
of the player's head and portions of a scanning hood overlying the
player's head.
17. The method for manufacturing the bespoke protective sports
helmet according to claim 16, wherein the step of capturing a scan
of a player's head with the scanning apparatus includes stitching
together images of portions of the player's head and portions of a
scanning hood overlying the player's head to generate a
three-dimensional representation of the player's head.
18. The method for manufacturing the bespoke protective sports
helmet according to claim 16, wherein the step of capturing a scan
of a player's head with the scanning apparatus further includes:
selecting a scanning helmet size; placing a scanning helmet of the
selected scanning helmet size on the player's head over the
scanning hood; capturing a helmet scan of the player wearing the
scanning hood and scanning helmet with a scanning apparatus; and
removing the scanning helmet from the player's head and capturing a
hood scan with the scanning apparatus while the player is wearing
the scanning hood.
19. The method for manufacturing the bespoke protective sports
helmet according to claim 12, wherein the step of forming a bespoke
pad based on the modified scan of the player's head includes
selecting a compression deflection rating of the at least one pad
member is selected based on at least one of the following factors:
i) player's impact history, ii) player's skill level, or iii)
player's position.
20. The method for manufacturing the bespoke protective sports
helmet according to claim 12, further comprising the step of adding
an identification device to the bespoke pad.
21. A method of assembling a protective sports helmet to be worn by
a player while participating in a sports activity, comprising:
placing a scanning helmet on the player's head; capturing a helmet
scan of the player wearing the scanning helmet; removing the
scanning helmet from the player's head; capturing a head scan of
the player head; aligning the head scan relative to the helmet scan
to form a registered head scan within a three-dimensional software;
comparing the registered head scan of the player's head against a
reference surface within the three-dimensional software to confirm
that the head scan does not penetrate the reference surface;
inwardly adjusting the registered head scan of the player's head by
a predetermined amount within the three-dimensional software to
create an inset head scan; selecting a pad from a group of pads
based on the inset head scan; and installing the selected pad into
a protective sports helmet shell.
22. The method of assembling the protective sports helmet according
to claim 21, wherein the step of inwardly adjusting the registered
head scan of the player's head by a predetermined amount results in
an increased thickness of the selected pad that is installed in the
protective sports helmet.
23. The method of assembling the protective sports helmet according
to claim 21, wherein the step of selecting the pad from the group
of pads based on the inset head scan includes comparing the
physical characteristics of each pad in the group of pads against
the inset head scan and the helmet shell.
24. The method of assembling the protective sports helmet according
to claim 23, wherein the physical characteristics of each pad in
the group of pads include thickness and compression deflection.
25. The method of assembling the protective sports helmet according
to claim 21, wherein the step of selecting the pad from the group
of pads based on the inset head scan includes selecting the pad
with a thickness rating that accounts for information obtained
based upon at least one of the following factors: i) player's
impact history, ii) player's skill level, or iii) player's
position.
26. The method of assembling the protective sports helmet according
to claim 21, wherein the step of selecting the pad from the group
of pads based on the inset head scan includes selecting the pad
with a compression deflection rating that accounts for information
obtained based upon at least one of the following factors: i)
player's impact history, ii) player's skill level, or iii) player's
position.
Description
TECHNICAL FIELD
This disclosure relates to (i) systems and methods for acquiring,
storing and processing a player's unique data, namely the player's
anatomical features, where that player is to wear an article of
protective sports equipment, (ii) for systems and methods of using
the player's unique data to manufacture an article of protective
sports equipment with a custom formed internal padding assembly
that substantially corresponds to the player's unique data, and
(iii) an article of protective sports equipment designed using the
acquired and processed unique player's data and including the
custom formed internal padding assembly that provides improved fit
and comfort for the player. Accordingly, the disclosure provides
for a system and method to design and manufacture bespoke
protective sports equipment that is purposely designed and
manufactured to match the player's anatomical specifications,
namely the topography and contours of the player's body part.
BACKGROUND
Most, if not all, contact team sports require players to wear
protective equipment, such as a helmet, while playing the sport
during both practice and game play. For example, youth, high
school, club, college and professional levels of football,
lacrosse, hockey, baseball and softball require players to wear a
protective helmet and protective equipment for a body part (e.g.,
shoulder pads for football, hockey and lacrosse, catcher's leg
guards and chest guards for baseball and softball). This protective
equipment generally comprises at least two layers: a substantially
rigid outer shell, typically formed from polymers and composite
materials including plastics, and an internal padding assembly,
which can be formed from a variety of impact absorbing materials.
Most protective helmets for contact team sports also include a chin
strap that secures the helmet on the player's head during the
course of play such that helmet is not dislodged when the player
and/or helmet receives a first impact whereby the helmet is
properly positioned to protect the player from a second impact.
Football and lacrosse helmets also include a face guard or face
mask that overlie the player's facial region. Hockey helmets
typically include a face guard, or clear shield that overlies at
least the player's eye region. Baseball batter's helmets typically
are "open-faced" and thus lack a face guard, although baseball
catcher's helmets include a face guard to protect the catcher.
Unlike baseball batter's helmets, softball batter's helmets include
a face guard, which typically extends over the player's mouth and
jaw region while leaving the eye region open.
Conventional protective equipment, including helmets can be found
in multiple standard sizes depending upon the playing level--youth,
varsity or professional--to which the helmet is intended for use.
For example, youth level football helmets can be found in a number
of standard sizes, including extra-small, small, medium, large and
extra-large, where the helmet size is based upon the circumference
of the player's head. Similarly, varsity and professional level
football helmets can be found in a number of standard sizes,
including small, medium, large and extra-large, where again the
helmet size is based upon the circumference of the player's head.
For example, a "medium" varsity level football helmet is sized for
a player having a head circumference of 20.375-22.0 inches, a
"large" varsity level football helmet is sized for a player having
a head circumference of 22-23.5 inches, and an "extra large"
varsity helmet is sized for a player having a head circumference of
23.5 inches and above. The football helmet's external shell and
internal padding assembly are configured to receive a player's
head, so a particular helmet size is selected for a player based
upon his/her head size, namely his/her head circumference. When
properly sized, the football helmet should provide a secure fit on
the player's head and be comfortable, while not irritating the
player when worn during the course of play.
It is not uncommon for the internal padding assembly found in
conventional protective sports helmets to be comprised of multiple
pad elements that can be selectively adjusted to a limited extent
in order to accommodate a player's (i) head size and (ii) head
contours or topography. However, the extent of that adjustment is
limited in a number of ways, including that the internal pad
assembly comprises an arrangement of pad elements each including an
elastically deformable, energy absorbing pad member positioned
within a pad housing. Thus, the internal pad assembly is configured
in a standard size with maximum dimensions and the internal pad
assembly must fit within a standardized helmet shell size. It is
understood that the helmet shell is formed to be substantially
rigid to withstand multiple impacts and the helmet shell's overall
configuration cannot be greatly expanded or contracted. An example
of a conventional internal padding assembly is one that features
multiple pad elements each with an inflatable component that allows
for a fluid, such as air, to be used to selectively inflate or
deflate the pad elements to better conform the internal padding
assembly to the player's head size and contours. Examples of a
conventional internal padding assembly can be found in U.S. Pat.
Nos. 6,934,971, 8,544,117, and U.S. patent application publication
US2015000808. Conformity of the internal padding assembly to the
player's head size and contours is limited by a number of factors
inherent to pad elements, including, but not limited to, the size
and configuration of the pad member, the size and configuration of
the pad housings, and the placement of the pad elements in the
padding assembly relative to the player's head. As the extent of
the adjustment of a conventional internal padding assembly to the
player's head contours and topography is limited, the player may
perceive the fit of the helmet to be inadequate and/or may not find
the fit of the helmet to be sufficiently comfortable. Thus, the
player wearing a conventional protective sports helmet might not be
entirely happy with the helmet, which may impact his/her selection
of the helmet and his/her performance while playing the contact
sport. Even if the player is happy with the comfort of the
conventional helmet and accepts the conventional helmet's fit on
his/her head, the helmet may not be ideally positioned and can be
susceptible to excessive movement when the helmet is impacted
during the course of play.
The apparatus, systems and methods disclosed herein address the
problems discussed above and other problems while providing
advantages and aspects not provided by conventional protective
sports helmets. A full discussion of the features and advantages of
the present disclosure is deferred to the following detailed
description, which proceeds with reference to the accompanying
drawings.
SUMMARY
The present disclosure provides systems and methods for acquiring,
storing and processing a player's unique data set concerning the
anatomical features of the player's body part (e.g., head) in order
to design and manufacture a piece of bespoke protective sports
equipment (e.g., helmet). The bespoke protective sports equipment
can include a custom formed internal padding assembly that can be
configured to match or substantially correspond to the player's
unique anatomical body part data. The bespoke equipment, including
its internal padding assembly, provides significantly improved fit
and comfort for the player. Accordingly, the disclosure provides
for a system and method to design and manufacture bespoke
protective sports equipment that is purposely designed to either
match or substantially correspond to the player's anatomical
specifications, namely the topography and contours of the player's
equipment body part and facial region, including the jaw
region.
The present disclosure also provides a method for manufacturing a
piece of bespoke protective sports equipment. In the context of a
bespoke helmet, the method may include placing a scanning hood on a
player's head, selecting a scanning helmet size and placing a
scanning helmet of the selected scanning helmet size on the
player's head over the scanning hood, adjusting the scanning helmet
according to the player's wearing preferences, capturing a helmet
scan of the player wearing the scanning hood and scanning helmet
with a scanning apparatus, removing the scanning helmet from the
player's head and capturing a hood scan with the scanning apparatus
while the player is wearing the scanning hood, opening the helmet
scan in three-dimensional software and properly aligning the helmet
scan with a shell template within the three-dimensional software,
opening the hood scan in the three-dimensional software and
properly aligning the hood scan with the properly-aligned helmet
scan within the three-dimensional software, comparing the
properly-aligned hood scan with data of the scanning helmet size
and determining whether scanning helmet size tolerances are
satisfied for the properly-aligned hood scan, creating at least one
insert file from the properly-aligned hood scan, fabricating an
insert from the insert file, placing the insert into a lower mold
section, attaching a backing material to an upper mold section,
heating an ethylene-vinyl acetate (EVA) cover and attaching the
heated EVA cover to the lower mold section, vacuum-forming the EVA
cover to an insert surface, pouring padding material into the
vacuum-formed EVA cover, allowing the poured padding material to
cool and solidify into a customized pad, removing the customized
pad from the vacuum-formed EVA cover and installing the customized
pad into the customized protective sports helmet.
The disclosure also provides for a bespoke protective sports
equipment fabricated from a process that comprises the numerous
steps discussed in the foregoing paragraph. Other features and
advantages of the disclosure will be apparent from the following
specification taken in conjunction with the following drawings.
Implementations of the described techniques may include hardware, a
method or process, or software for a mobile device on a
computer-accessible medium. The details of one or more
implementations are set forth in the accompanying drawings and the
description below. Other features will be apparent from the
description and drawings, and from the claims.
Additional advantages and novel features will be set forth in part
in the description which follows, and in part will become apparent
to those skilled in the art upon examination of the following and
the accompanying drawings or may be learned by production or
operation of the examples. The advantages of the present teachings
may be realized and attained by practice or use of various aspects
of the methodologies, instrumentalities and combinations set forth
in the detailed examples discussed below.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing figures depict one or more implementations in accord
with the present teachings, by way of example only, not by way of
limitation. In the figures, like reference numerals refer to the
same or similar elements.
FIG. 1A is a perspective view of a bespoke helmet according to
exemplary embodiments of the present disclosure.
FIG. 1B is a rear view of the bespoke helmet of FIG. 1.
FIG. 1C is an upper perspective view of a customized internal
padding assembly according to exemplary embodiments of the present
disclosure.
FIG. 1D is a rear perspective view of the customized internal
padding assembly of FIG. 1C.
FIG. 1E is a lower perspective view of the customized internal
padding assembly of FIG. 1C.
FIG. 1F is a front view of a customized internal padding assembly
according to exemplary embodiments of the present disclosure.
FIG. 1G is an upper perspective view of a customized internal
padding assembly according to exemplary embodiments of the present
disclosure.
FIG. 1H is a rear perspective view of the customized internal
padding assembly of FIG. 1G.
FIG. 1I is a lower perspective view of the customized internal
padding assembly of FIG. 1G.
FIG. 2A illustrates a side view of a player wearing a scanning hood
according to exemplary embodiments of the preset disclosure.
FIG. 2B illustrates a surface of a scanning hood according to
exemplary embodiments of the present disclosure.
FIG. 3A illustrates a scanning helmet and a scanning apparatus
according to exemplary embodiments of the present disclosure.
FIG. 3B illustrates the scanning helmet and scanning apparatus of
FIG. 3A.
FIG. 4A illustrates a customized padding assembly disposed on a
schematic representation of a player according to exemplary
embodiments of the present disclosure.
FIG. 4B illustrates a bespoke helmet with a customized padding
assembly, both disposed on a schematic representation of a player
according to exemplary embodiments of the present disclosure.
FIG. 5A illustrates an external view of a mold assembly according
to exemplary embodiments of the present disclosure.
FIG. 5B illustrates a cross-sectional view of the mold assembly of
FIG. 5A, taken along line B-B of FIG. 5A, and further showing
customized casting elements.
FIG. 5C illustrates an exploded perspective view of the mold
assembly and associated customized casting elements of FIG. 5B.
FIG. 6A is an upper perspective view of a customized padding
assembly according to exemplary embodiments of the present
disclosure.
FIG. 6B is a rear perspective view of the customized padding
assembly of FIG. 6A.
FIG. 6C is a lower perspective view of the customized padding
assembly of FIG. 6A.
FIG. 6D is a perspective view of a partially-bespoke helmet
according to exemplary embodiments of the present disclosure.
FIG. 7 illustrates a method of gathering customized data regarding
topographical features of a player according to exemplary
embodiments of the present disclosure.
FIG. 8 illustrates a method of analyzing and modifying acquired
customized data according to exemplary embodiments of the preset
disclosure.
FIG. 9 illustrates a method of creating inserts from insert
manufacturing files using additive manufacturing according to
exemplary embodiments of the preset disclosure.
FIG. 10 illustrates a method of creating inserts from insert
manufacturing files using subtractive manufacturing according to
exemplary embodiments of the preset disclosure.
FIG. 11 illustrates a method of casting customized pads using
inserts according to exemplary embodiments of the preset
disclosure.
FIG. 12 illustrates a method of casting customized pads using
inserts, distinct from that shown in FIG. 11, according to
exemplary embodiments of the preset disclosure.
DETAILED DESCRIPTION
In the following detailed description, numerous specific details
are set forth by way of examples in order to provide a thorough
understanding of the relevant teachings. However, it should be
apparent to those skilled in the art that the present teachings may
be practiced without such details. In other instances, well known
methods, procedures, components, and/or circuitry have been
described at a relatively high-level, without detail, in order to
avoid unnecessarily obscuring aspects of the present
disclosure.
While this disclosure includes a number of embodiments in many
different forms, there is shown in the drawings and will herein be
described in detail particular embodiments with the understanding
that the present disclosure is to be considered as an
exemplification of the principles of the disclosed methods and
systems, and is not intended to limit the broad aspects of the
disclosed concepts to the embodiments illustrated.
This disclosure relates to (i) systems and methods for acquiring,
storing and processing a player's unique data, namely the player's
anatomical features, where that player is to wear protective sports
equipment worn against a body part while engaged in a sporting
activity, (ii) for systems and methods of using the player's unique
data to manufacture a piece or article of protective sports
equipment with a custom formed internal padding assembly that at
least substantially corresponds to the player's unique data, (iii)
for systems and methods of using the player's unique data to
manufacture the bespoke protective sports equipment with both a
custom formed shell and internal padding assembly that match the
player's unique data. As one example of the protective sports
equipment, a protective sports helmet is designed using the
acquired and processed unique player's data and including the
custom formed internal padding assembly that provides an improved
fit for the player. As used herein, the term "player" is a person
who wears the protective sports equipment (e.g., helmet or shoulder
pads), is gender neutral and is synonymous with the terms "helmet
wearer" or "wearer." The term "anatomical features" means the
dimensions, topography and contours of the player's body part
(e.g., head including the player's skull, facial region, eye region
and jaw region). Because the disclosed protective equipment is worn
on the player's body part (e.g., head, shoulder, knee, elbow, hip,
shins) the "anatomical features" term includes the outer
configuration of the player's body part. In the context of a
bespoke helmet, the internal padding assembly makes contact with
the player's hair, the "anatomical features" term also includes the
type, amount and volume of the player's hair or lack thereof. For
example, some players have long hair, while other players have no
hair (i.e., are bald).
The inventive bespoke protective sports equipment and system can be
configured as a shoulder pad assembly, an elbow pad, a thigh pad, a
knee pad, a shin guard, a chest guard, or a hip pad. Shoulder pad
assemblies typically include two arches that overlie the shoulder
region, an extent of the back region and an extent of the chest
region of the player, as well as an internal padding assembly
affixed to the arches. In the context of a protective sports helmet
worn by a player engaged in football, hockey or lacrosse, the
disclosed helmet is "bespoke," meaning that the internal padding
assembly is customized to the player wearing the helmet because it
is purposely designed, configured and manufactured to match
anatomical features of the player's head. Much like a tailor
provides a bespoke suit that is made to order with pants and a
jacket that match the customer's specific anatomical needs (e.g.,
waist size, chest size, sleeve length), the system and methods
disclosed allow for a bespoke protective sports helmet that
provides improved fit and comfort for the player wearing the
helmet. In another embodiment, the helmet is "fully bespoke,"
meaning that both the helmet shell and the padding assembly are
purposely designed, configured and manufactured to match the
anatomical features of the player's head. In yet another
embodiment, the disclosed helmet and its internal padding assembly
are "partially bespoke," meaning that the helmet and the padding
assembly are purposely designed and configured to substantially
correspond to the anatomical features of the player's head. In this
embodiment and as explained below, the internal padding assembly of
the partially bespoke helmet is comprised of an arrangement of pads
that are selected from a large number of pre-manufactured pads. In
all three versions--bespoke, fully bespoke and partially
bespoke--highly sensitive scans of the player, with and without a
helmet, are conducted to capture his/her anatomical features to
help design the internal padding assembly.
The disclosed system and methods may be used to design and
manufacture an article of bespoke protective equipment worn against
the player's body part while engaged in playing the sport. The
following paragraphs focus on the system and methods used to design
and manufacture a bespoke protective sports helmet for a football
player, hockey player, or lacrosse player or any other player in a
contact sport wherein the helmet is designed and intended to
receive, withstand and absorb multiple impacts during the course of
play. As discussed below, the disclosed bespoke protective sports
helmet for football, hockey and lacrosse players include at least
two layers: (i) an outer shell typically formed from polymers and
composite materials, including plastics and carbon fiber-reinforced
polymers, and (ii) an internal energy attenuating assembly which is
formed from cast urethane foam and is configured to match the
player's head topography. The outer shell can be formed from
materials that provide it with a generally rigid configuration in a
pre-impact state, however, the outer shell may experience some
elastic localized deformation in response to an impact or series of
impacts in an impact state. Because this localized deformation is
elastic, the outer shell returns to its original configuration of
the pre-impact state. The disclosed system and methods may also be
used to design and manufacture a bespoke protective helmet for
baseball, namely a batter's helmet or a catcher's helmet, where
these helmets can receive a number of high velocity impacts from a
thrown or batted baseball.
Bespoke Helmet and System
In the bespoke helmet and system embodiment, the disclosed system
and methods include a number of processes and sub-processes that
are used to acquire and process data concerning the player's unique
anatomical features and then use the processed data to manufacture
a bespoke protective sports helmet, or a customized helmet, 2,
exemplary shown in FIG. 1A, with a customized internal padding
assembly 4, exemplary shown in FIG. 1C that matches the player's
unique data. The bespoke helmet 2 includes a face guard or facemask
13 and a chin strap assembly 17 that secures the helmet 2 to a
desired wearing position on the player wearing the helmet 2. Those
processes and sub-processes, as well as the bespoke protective
sports helmet, are discussed below.
A method for acquiring, storing and processing a player's unique
data, namely the player's anatomical features, commences with
conducting at least two scans of the player's head H and facial
region F where one scan involves the player P wearing a scanning
hood 10 and a scanning helmet 15, and a second scan involves the
player P wearing only the scanning hood 10. A person skilled in the
art recognizes that the order of the first and second scans can be
reversed. FIGS. 2A-3B and 7 illustrate a process for acquiring the
player's unique anatomical feature data while he or she is wearing
the scanning hood 10 alone, and wearing both the scanning hood 10
and the scanning helmet 15. As an initial step, the scanning hood
10 is placed on, or over, the head H of the player P. The scanning
hood 10 may be a flexible apparatus sized to fit over the player's
head H and achieve a tight or snug fit around the player's head H
due to elastic properties and dimensions of the scanning hood 10,
as can be seen in FIG. 2A. The scanning hood 10 provides for
increased accuracy when performing a scan of the player's head H by
conforming to the anatomical features the player's head H and
facial region F, namely the topography and contours of the head H
and facial region F, while reducing effects of hair. The scanning
hood 10 may be made from neoprene, lycra or any other suitably
elastic material known to those skilled in the art. Once the
scanning hood 10 is placed over the player's head H, the player
and/or another person such as an operator may verify that the
scanning hood 10 is appropriately positioned and oriented on the
player's head H. The scanning hood 10 is re-adjusted if the
scanning hood 10 is found to not be appropriately positioned on the
player's head H or is uncomfortable. In some embodiments, it is
ensured that the scanning hood 10 fully covers the portions of the
player's head H (e.g., upper jaw regions) that contact a customized
internal padding assembly 4. In some embodiments, the scanning hood
10 is positioned to fully cover the player's brow line, including
the eyebrows. In the event the body part to be scanned is not the
player's head, the hood 10 can be configured as a body part
scanning interface article, such as a wrap or sleeve, that envelops
the body part to be scanned and subsequently protected by the
bespoke protective body part equipment.
A size for the scanning helmet 15 is then selected from a range of
scanning helmet 15 shell sizes. As an example for an adult player
P, the scanning helmet 15 shell sizes may include medium, large and
extra-large, although additional or intermediate sizes are
certainly within the scope of this disclosure. The selection of the
scanning helmet 15 shell size may be by determined by previous
player experiences or by estimations or measurements taken during
or before the acquisition of the player's unique data. Once the
size of the scanning helmet 15 is selected, the scanning helmet 15
is placed over the player's head H while the player P is wearing
the scanning hood 10. After the scanning helmet 15 is placed on the
player's head H, the player adjusts the scanning helmet 15 to a
preferred wearing position or configuration, which includes
adjusting the chin strap assembly 17 by tightening or loosening it.
It is not uncommon for a player P to repeatedly adjust the scanning
helmet 15 to attain his or her preferred wearing position because
this position is a matter of personal preference. For example, some
players prefer to wear their helmet lower on their head H with
respect to their brow line, while other players prefer to wear
their helmet higher on their head H with respect to their brow
line. The preferred wearing position is also a function of the face
guard 13 and the player looking through the face guard 13 to assess
the field of view.
As can be seen in FIGS. 3A and 3B, the scanning helmet 15 includes
the chin strap 17, one or more apertures 20 formed in the helmet
shell and an internal scanning padding assembly 16. The position,
number and shape of the apertures 20 in the scanning helmet 15 are
not limited by this disclosure. These apertures 20 allow certain
portions of the scanning hood 10 to be seen when the scanning
helmet 15 is worn over the scanning hood 10 on the player's head H.
In some embodiments, one or more reference markers 21 (shown
exemplarily in FIG. 2A) are placed on particular points on the
scanning hood 10 through the apertures 20, or on other parts of the
scanning hood 10 not covered by the scanning helmet 15, while the
scanning hood 10 and scanning helmet 15 are being worn by the
player. The particular points may correspond with markings on the
scanning hood 10, or with the apertures 20 or other features on the
scanning hood 10 or scanning helmet 15. The reference markers 21
are used to aid in the orientation and positioning of the scanning
helmet 15 and/or the scanning hood 10 relative to each other,
relative to features on the scanning hood or helmet, or relative to
the player's head H, as will be described below. The reference
markers 21 may attach to the scanning hood 10 using adhesives or
using any other mechanical or chemical attachment means, and
further may be colored or include electronic properties or features
that affect their visibility during scanning, and the reference
markers 21 may appear in a hood scan and a helmet scan taken of the
player P.
As mentioned above, the scanning helmet 15 includes the face guard
13 that is removably attached to a forward portion of the scanning
helmet 15. The face guard 13 may be used by the player, when
wearing the scanning helmet 15, to assist the player in determining
a preferred helmet wearing position. Once the player positions the
scanning helmet 15 such that a preferred helmet wearing position is
achieved, the face guard 13 is removed, as exemplarily shown in
FIG. 3B, to increase the accuracy of the helmet scan by allowing a
scanning apparatus 22 to capture a greater, and less obscured,
portion of the player's face. Although the face guard 13 is
removed, the chin strap assembly 17 remains secured around the
player's chin and jaw thereby securing the scanning helmet 15 in
the preferred helmet wearing position during the subsequent
scans.
After the player P determines and indicates to an operator that the
scanning helmet 15 is properly positioned on the player's head H,
the operator conducts a first helmet scan of the player P and the
scanning helmet 15 while the player P is wearing both the scanning
hood 10 and the scanning helmet 15. The player P and helmet scan is
taken by a scanning apparatus 22 utilizing one or more image
sensors (e.g., cameras), lasers (e.g., LiDAR) or other scanning
technologies (e.g., contact scanning, laser triangulation scanning
or structured light scanning). In some embodiments, the scanning
apparatus 22 is a single, hand-held unit, such as a personal
computer, tablet or cell phone that an operator holds and moves
around the player's head H and the scanning helmet 15 to capture
images of both. In some embodiments, a plurality of scanning
apparatuses 22 is arranged in a pre-determined pattern and
orientation relative to the scanning subject, or player P. In some
embodiments, photographs are taken of the player P wearing the
scanning helmet 15 and used for reference to properly align a hood
scan, as described below. Further, physical measurements of the
player P wearing the scanning helmet 15 can be taken and used to
properly align the hood scan. Regardless of whether a single
scanning apparatus 22 or multiple apparatuses 22 are employed, a
plurality of scanning images, or a substantially continuous moving
set of images, can be captured and recorded. These images can then
be "stitched" or electronically combined together in various ways
to produce a single three-dimensional scan, or data file.
In some embodiments, the reference markers 21 on certain portions
of the scanning hood 10 can be raised or recessed structures (e.g.,
dimples). The number of markers 21 on the scanning hood 10 is such
that there are enough markers 21 to allow for the accurate creation
of the three-dimensional model, but low enough to make processing
of the model efficient. For example, four and twelve markers 21 per
square inch may be used. A person skilled in the art recognizes
that more or fewer markers 21 may be used to alter the processing
times and the accuracy of the model.
The markers 21 on the scanning hood 10 contain unique portions 27
to enable the computerized modeling system to efficiently and
accurately process the images or video. An example of such unique
portions 27 is exemplarily shown in FIG. 2B. One method of creating
these unique portions 27 is to divide each dimple into four
sections and fill each section with a different color. It is to be
understood that more or fewer than four sections can also be
employed, and that different patterns in each section can also be
employed. In addition, to ensure that the computerized modeling
system can distinguish each unique portions 27 from one another,
the color sections of the unique portions 27 may be rotated
relative to each other. For example, a top section of a unique
marker may be colored red, while the adjacent unique marker may
have the bottom section colored red. A person skilled in the art
recognizes that uniquely marking each unique marker can be
accomplished in other ways or combinations of other ways, including
using different shapes, textures, numbers, letters, etc.
A scanning apparatus 22, such as a camera, is then utilized to
obtain either two-dimensional images or video of the scanning hood
10 from a number of different angles or points of view. The images
or video are then provided to a computerized modeling system, which
first roughly detects the edges of scanning hood 10 in each image
or frame of the video. For example, Sobel edge detection or Canny
edge detection may be used. The computerized modeling system may
then remove parts of the images or frames of the video that are
known to not be contained within the scanning hood 10. This reduces
the amount of data that will need to be processed by the
computerized modeling system in the following steps. In addition,
the removal of the parts of the images or frames of the video that
are known to not be contained within the scanning hood 10 reduces
the chance of errors in the following steps, such as the
correlating or matches of a reference marker 21 with the background
of the image.
Next, the computerized modeling system processes each image or
frame of video to detect the reference markers 21, which in some
embodiments are the unique markers 27 on the scanning hood 10.
After detecting the reference markers 21, the computerized modeling
system correlates or matches as many reference markers 21 in each
image to other reference markers 21 in other images or frames of
the video. This reference marker 21 matching informs the
computerized modeling system of the alignment or position of each
image or frame of video. Once the alignment or position of each
image or frame of video is known, mathematical algorithms are
utilized to reconstruct a three-dimensional model of the player
with the scanning hood 10. Typically, this three-dimensional model
of the scanning hood 10 is represented in wire-frame form: a
wire-frame model is a mathematical model in which points that are
adjacent on a mathematical surface are connected by line segments.
Illustrations of a wire-frame model for a player wearing a scanning
hood 10 are shown in FIGS. 4A and 4B.
Once the three-dimensional model of the player with the scanning
hood 10 is created, the computerized modeling system determines the
scaling factor of the model. This is possible because the size of
the reference markers 21 is known and fixed. Thus, the computerized
modeling system determines the scaling factor of the model by
comparing the known size of the reference markers 21 to the size of
the reference markers in the model. Once this scaling factor is
determined, the model can be used to accurately represent the
player P.
After the helmet scan, or player and helmet scan, is taken, an
operator confirms that the helmet scan is of adequate quality based
upon predetermined quality criteria, and/or a visual or manual
inspection of the helmet scan. These scan quality criteria include
scan continuity, the inclusion of wrinkles or other perturbations,
and recognition and/or visibility of the reference markers 21 or
player facial features. If the helmet scan quality is determined to
be of inadequate quality, a new helmet scan is taken of the player
P and the scanning helmet 15. If this second helmet scan quality is
determined to satisfy the scan quality criteria and/or the visual
or manual inspection, then this helmet scan is then saved to a
local storage or uploaded to a remote storage or cloud storage
device hosted by a separate entity and accessible to the operator.
The helmet scan can be saved as a helmet scan data file, and the
helmet scan data file can be saved and/or uploaded to a central
server.
Following a successful helmet scan, the scanning helmet 15 is
removed from the player's head H. The scanning helmet 15 is removed
such that the reference markers 21 on the scanning hood 10 are not
disturbed or displaced. While the player P is wearing the scanning
hood 10, but not the scanning helmet 15, a hood, or a player and
hood, scan is taken with the scanning apparatus 22. The hood scan
can be taken by one or more scanning apparatuses 22 in a manner
similar to the process described above for taking the helmet scan.
Similar to the helmet scan, after the hood scan has been taken, the
operator confirms that the hood scan satisfies the scan quality
criteria, or is approved by a visual or manual inspection of the
hood scan. The scan quality criteria include the scan continuity,
the inclusion of wrinkles or other perturbations, and a recognition
and visibility of the reference markers 21 and player facial
features. If the hood scan quality is determined to be of
inadequate quality, a new hood scan is taken. If this second hood
scan quality is determined to satisfy the scan quality criteria
and/or the visual or manual inspection, then this hood scan is then
saved to a local storage or uploaded to a remote storage or cloud
storage device hosted by a separate entity and accessible to the
operator. The helmet scan can be saved as a helmet scan data file,
and the helmet scan data file can be saved and/or uploaded to a
central server.
The player P removes the scanning hood 10 from his or her head H
after the hood scan is saved or uploaded. Following each of the
helmet scan and the hood scan, the player P may be shown a
resulting two-dimensional or three-dimensional image from each
respective scan.
A method for acquiring, storing and processing a player's unique
data, namely the player's anatomical features, continues with
processing both the player and helmet scan or "helmet scan," and
the player and hood scan or "hood scan." As exemplarily shown in
FIG. 8, the uploaded helmet and hood scans, or uploaded helmet scan
data file and hood scan data file, are opened in software on a
computer or other electronic device. In some embodiments, the
software is three-dimensional software, which may be Pro/ENGINEER,
PTC Creo, SolidWorks, Fusion 360 or Rhinoceros. The uploaded helmet
and hood scans, or uploaded helmet scan data file and hood scan
data file, can be opened within or alongside, a general helmet
shell template image, a minimum certified surface (MCS) template
image, blank insert files in the three-dimensional software and/or
a customized player helmet shell template or a "helmet shell
template" that includes a plurality of layers including, but not
limited to, one or more shell size reference layers, a Minimum
Certified Surface (MCS) layer and an insert blank layer, as will be
described below. The helmet shell template may be a pre-loaded
image, model or set of coordinates corresponding to an existing
helmet shell, while the MCS layer may be an image or set of
coordinates useful in determining whether certain tolerances are
satisfied through comparisons with other electronic files or data.
Similar to the process described above, at this stage, an operator
confirms that the helmet and hood scans satisfy scan quality
criteria. Such a confirmation can be performed using numerical
quality criteria or algorithms, and/or by a visual or manual
inspection of the helmet and hood scans or of the uploaded helmet
scan data file and hood scan data file.
Following a confirmation of adequate helmet scan quality, the
helmet scan is selected and aligned three-dimensionally within the
three-dimensional software. In some embodiments, the helmet scan is
aligned in three-dimensional space according to a pre-set template,
which may be the helmet shell template. The proper alignment of the
helmet scan may be made with reference to a predetermined set of
coordinates or reference points, a helmet shape or the player's
facial features (e.g., brow region, upper lip region, nose bridge
or nose tip) within the helmet shell template, or using another
method or reference system. In particular, the helmet scan can be
aligned with one or more of the helmet shell size reference layers
within the helmet shell template, or one or more features
represented in the one or more of the helmet shell size reference
layers within the helmet shell template. Such an alignment can be
made along, or according to, multiple axes. A confirmation that the
helmet scan is properly aligned in the three-dimensional software
and/or the shell template is then made. Such a confirmation can
include a visual and/or manual inspection of the alignment. When
the helmet scan is determined to be improperly aligned in the
three-dimensional software and/or with the helmet shell template,
the helmet scan is realigned until the helmet scan is properly
aligned in the three-dimensional software and/or with the helmet
shell template.
Following a confirmation of adequate hood scan quality, the hood
scan is selected and then aligned three-dimensionally within the
three-dimensional software. The proper alignment of the hood scan
may be made with reference to a predetermined set of coordinates,
reference points, reference markers 21 and/or facial features
within the properly-aligned helmet scan or using another method or
reference. In some embodiments, the facial features in the hood
scan, which may include the player's brow region, brow, nose
bridge, nose tip or upper lip region, are aligned with a
corresponding player facial feature in the properly-aligned helmet
scan. Such an alignment can be made along multiple axes. The
properly-aligned helmet scan, or reference markers 21 therefrom,
may be simultaneously viewed from multiple perspectives when the
hood scan, or reference markers 21 therefrom, is selected and
viewed.
In some embodiments, the reference markers 21 and/or the nose
region of the player are identified in the hood scan and used to
properly align the hood scan in the three-dimensional software with
respect to the properly-aligned helmet scan, reference markers 21
and/or the player's nose bridge, nose tip or brow in the helmet
scan, or other reference means or markers from the properly-aligned
helmet scan. A confirmation that the hood scan is properly aligned
with respect to aspects of the properly-aligned helmet scan, the
hood template or another pre-determined set of coordinates in the
three-dimensional software is then made. Such a confirmation can
include a visual and/or manual inspection of the alignment. When
the hood scan is found to be improperly aligned with respect to the
above-mentioned criteria, the hood scan is realigned until it is
properly aligned in the software program.
The properly aligned hood scan may then be compared with known
helmet shell size data, or to the properly aligned helmet scan, to
check for certain relative tolerances and relationships. In some
embodiments, the properly aligned hood scan is compared with the
Minimum Certified Surface (MCS) layer in the helmet shell template
corresponding to a given helmet shell size. The MCS is a reference
surface defined by a collection of minimum distance values between
an outer surface of the player's head H and a helmet shell. An
internal padding assembly typically occupies the MCS when the
internal padding assembly is installed in a shell of a protective
sports helmet. Consistent with industry standards, every NOCSAE
certified protective sports helmet has an MCS. Ideally, the
player's head H should not penetrate or extend into the MCS when
the player P wears the protective sports helmet. An MCS value, or
set of values, may vary based on a given helmet shell location or
padding location within the helmet shell. Data from the properly
aligned hood scan and/or properly aligned helmet scan can be used
to determine whether such an MCS is satisfied based on known
measurements of a given helmet shell size. Further, the MCS layer
of the helmet shell template, or a separate MCS template or data
set, can instead, or additionally, be compared with customized
insert files to determine satisfaction of MCS tolerances, as
described below. If the MCS, or another tolerance measurement, is
satisfied through the comparison of aligned hood scan data and the
MCS layer of the helmet shell template for the selected shell size,
it is determined that a customized helmet manufactured using the
presently disclosed methods can be made for that player P using the
given helmet shell size.
If, however, the MCS, or other tolerance measurement, is not
satisfied through a comparison of aligned hood scan data and known
measurements of a helmet shell size or the MCS layer of the helmet
shell template for the shell size, it is determined that a bespoke
helmet manufactured using the presently disclosed methods cannot be
made for that player P using the given helmet shell size. In this
scenario, the player or scan operator will then select a larger
helmet shell size and perform a new helmet scan and hood scan using
a scanning helmet corresponding to the larger helmet shell size.
This selection process can continue until a helmet and hood scan
are produced where data from the properly aligned hood scan
satisfies the MCS layer of the helmet shell template, or other
tolerance measurement, such that a comparison of aligned hood scan
data and the MCS layer of the helmet shell template for the
selected shell size allows a customized helmet manufactured using
the presently disclosed methods to be made for that player using
the given selected helmet shell size.
When the MCS, or other tolerance measurement, is not satisfied
through a comparison of aligned hood scan data and the MCS layer of
the helmet shell template for the selected shell size, or known
measurements of a given helmet shell size, and it is determined
that a customized helmet manufactured using acquired customized
helmet data cannot be made for that player using the given helmet
shell size, the scan operator may compare the aligned hood scan
data to known measurements of a helmet shell larger than the
selected helmet shell size. When such a larger helmet shell size is
selected and the aligned hood scan data satisfies the MCS layer of
the helmet shell template of the larger shell size or known data of
the larger helmet shell size, a customized protective sports helmet
can be manufactured using the larger shell size.
Additionally, at least a portion of the properly-aligned and
MCS-verified hood scan may be inset by a pre-determined distance
and/or a player-preferred distance, as is further described below,
to create a compression fit when the helmet is worn on the head of
the player. This results in a customized padding assembly slightly
compressing to form an interference fit with the player's head H
when the helmet is worn by the player P. Such alterations include
changing the size, shape, orientation or number of customized pads
used in the manufacturing of the customized helmet.
Following the selection of an appropriate helmet shell size for a
given player's customized helmet data, insert files, or insert
manufacturing files, are created in order to form a set of inserts
for the formation of customized helmet pads 54 that form the
customized internal padding assembly 4. The insert files are
created using the acquired and processed unique player and helmet
data acquired from the aligned helmet and hood scans, and may
further be created using an insert layer of the helmet shell
template. Boolean operations can be used to create the insert
files, as will be described below. The insert files may also
incorporate various additional factors, variables or considerations
in addition to the player's unique data gathered from the aligned
helmet and hood scans. For example, the insert files may be
adjusted based on the helmet shell size selected.
In some embodiments, a degree of inward pressure against a player's
head H is desired while the bespoke helmet is worn by the player P.
The inward pressure may be created by the shape, size and/or
orientation of one or more customized pads, an arrangement of
multiple customized pads, the helmet shell, a spacing element
disposed between the helmet shell and one or more of the customized
pads, and/or other features of the bespoke helmet. According to
some embodiments, the inward pressure is generated by expansive, or
restoring, forces of one or more pads that are slightly compressed
when the player P wears the helmet on his or her head H relative to
the pads' relaxed state when the customized helmet is not worn by a
player P. The existence or degree of inward pressure can be
selected from a range of pre-set degrees, or can be specified by
the manufacturer of the customized helmet along with input from the
player P. In other words, the insert files can be designed to
create inserts that form a customized padding assembly with
non-compressed inner dimensions that are less than a volume
occupied by the player's head H, and/or the player P wearing the
scanning hood.
In some embodiments, the creation of the insert files accounts for
such inwardly directed pressure applied by the internal padding
assembly on the player's head H. The inward pressure can be
created, or adjusted, by altering the acquired player data and/or
helmet data and measurements. For example, an insert file is
adjusted to create a dimensional inset in a customized internal pad
manufactured using the insert file. The resulting dimensional inset
may increase the customized pad's thickness at one or more
locations or the pad's overall thickness. As a result, the
customized helmet has customized internal pads that feature an
inner surface that is dimensioned further from the inner surface of
the helmet shell and thereby slightly compress to form an
interference fit with the player's head H when the helmet is worn
by the player P. Such alterations include changing the size, shape,
orientation or number of customized pads used in the manufacturing
of the bespoke helmet. Further, the insert files can additionally
compensate for a thickness of the scanning hood by including an
additional compensating dimensional inset, corresponding to the
thickness of the scanning hood, to more accurately reflect the
actual topography of the player's head H, rather than the scanning
hood on the player's head H. These alteration factors may be
applied to any of the helmet scan, hood scan, properly-aligned
helmet scan, properly-aligned hood scan and insert files during the
processing of the images that allow for the manufacture of the
customized helmet.
In some embodiments, a three-dimensional blank insert is placed
near, or on, the properly-aligned hood scan in the
three-dimensional software. The three-dimensional blank insert may
be included with the insert layer of the helmet shell template.
Then, optionally, the properly-aligned hood scan is inset by a
particular distance or degree, which may be specific for the
creation of that particular customized pad. A Boolean operation, or
intersection calculation, may then be performed between a surface
of the three-dimensional blank insert and at least a portion of the
aligned, or aligned and inset, hood scan. An insert file is then
created, a surface of which reflects the player's head topography
in the surface of the insert file.
In some embodiments, the creation of the insert file accounts for
various player preferences regarding the fit of one or more padding
elements. For example, if a player prefers a looser or tighter
fitting crown pad, such a preference can be accommodated for in the
making of the customized helmet with customized pads. The
preference can be accommodated by altering the size, shape,
orientation or number of the customized internal pads used in the
manufacturing of the customized helmet. This preference factor may
be applied to any of the helmet scan, hood scan, properly-aligned
helmet scan, properly-aligned hood scan and insert file.
Additionally, the insert files may be refined, smoothed or
optimized manually, by software or by electronic computer-based
tools based on a range of factors including, but not limited to,
electronic errors, non-continuous surfaces, overlapping surfaces,
meshing inconsistencies, meshing anomalies and/or meshing gaps.
Such operations may be performed without substantially, or in any
degree, altering a shape of any of the aforementioned scans or
files, and merely may refine or optimize the electronic files in
preparation for customized helmet manufacturing.
The customized internal padding assembly 4, as exemplarily shown in
FIGS. 1G-1I comprises individual pad members for use in the
customized helmet. For example, the customized pad members include
a customized front pad 80, a customized crown pad 81, a customized
rear pad 82, a customized left side pad 83, a customized right side
pad 84, a customized occipital pad 85, a customized left jaw pad 86
and a customized right jaw pad 87, wherein the jaw pads overlie an
extent of the jaw or mandible of the player when the bespoke helmet
is worn. It is to be understood that the insert files may be used
to create more or fewer customized pads for a given customized
helmet. One insert file may be used to create one customized pad,
or a single insert file may be used to create multiple customized
pads. The insert files, which may be polygon mesh files and/or
files in .mesh format, may be checked for file quality, mesh
quality and mesh continuity. The insert files may be exported, or
converted, to a STereoLithography (STL) or an OBJ/.OBJ file format.
The insert files are saved to a local storage device or uploaded to
a remote storage device, which may be a remote storage device, a
cloud storage system or a central server.
The above steps substantially complete the method for acquiring,
storing and processing a player's unique data and the processing of
both the helmet scan and the hood scan.
The systems and methods of using the player's unique data to
manufacture the customized helmet with a customized internal
padding assembly that substantially corresponds to the player's
unique data includes creating inserts 40 that are used to form the
customized internal padding assembly. Inserts 40, created using the
insert files, are best illustrated in FIGS. 5A-5C. The inserts 40
are unique for each player, and further are unique for each
customized pad or group of pads fabricated for use in a customized
helmet. A given insert 40 is created from an insert file using an
additive or subtractive manufacturing process. The additive
manufacturing process includes three-dimensional printing. In such
a process, the insert file is transferred to a three-dimensional
printing apparatus, which then three-dimensionally prints a
corresponding insert 40. The additive manufacturing process creates
the insert by, continuously or sequentially, adding material to
create the insert 40. The material used to create the insert 40 can
be any number of polymers, metals, ceramics or other materials.
A subtractive manufacturing process includes machining and any
number of machining tools known to those skilled in the art. Such
machine tools comprise mills, lathes, saws, drills, bores and
reamers, among many others, and operate using manual controls
and/or Computer Numeric Controls (CNC). Such CNC machine tools
incorporate Computer-Aided Manufacturing (CAM) controls and
software to enable precise electronic control of the manufacturing
process, and CAM cutting paths may be calculated, before
subtractive manufacturing, based on the insert file. The
subtractive manufacturing process creates the final insert 40 from
a blank made of any number of polymers, metals or ceramics by
removing material from the blank with one or more machine
tools.
Following insert 40 creating using either the additive or
subtractive process, the inserts 40 may be checked for adequate
quality, continuity and other properties for use in the
manufacturing of customized components for a customized protective
sports helmet. Inserts 40 determined to be of adequate quality,
continuity and/or other properties for use in the manufacture of a
customized protective sports helmet pad are used in the creation of
customized helmet pads.
The disclosure continues with the manufacture of customized
protective helmet pads. An example of an apparatus for
manufacturing bespoke helmet pads, as illustrated in FIGS. 5A-5C,
includes a mold 28. The mold 28, which can be called a master mold,
includes one or more components used to cast customized, or
bespoke, helmet components or helmet pads. In some embodiments, the
mold 28 includes an upper section 32 and a lower section 36. The
upper section 32 and lower section 36 form an internal cavity 44
when the upper section 32 is placed on top of the lower section 36.
The mold 28 may be made from any suitable material, and is made of
urethane in some embodiments.
Prior to casting, a weight of the urethane casting material is
verified based upon volume calculations derived from the Boolean
operations and/or insert files, described above. Further, a ratio
of isocyanate and resin may be verified for the customized pad, or
customized part, being created. The ratio may be determined for a
particular type of pad, such as a front pad, and/or may be
determined for a particular player based on one or more of player
preferences, player head topographical features, player history,
player skill level and player position. It may be understood that
various properties of a finished and cast customized pad, such as
hardness and compression deflection ratings, may be altered by
adjusting the aforementioned ratio of isocyanate and resin.
One or more inserts 40, created as described in the preceding
sections, are placed into the internal cavity 44, and the insert 40
may be placed substantially within a portion of the internal cavity
44 formed in the lower section of the mold 36. A velcro panel, or a
loop panel, may be affixed to a portion of the upper mold section
32. The loop panel may be affixed to the upper mold section 32
using adhesives, or any other mechanical attachment system.
A backing material 48, which in some embodiments is nubuck, may
then be secured to the upper section of the mold 32 via a
positioning apparatus, or a backing loop, adhesives, magnets,
vacuum-forces or any other mechanical attachment system. The
backing loop can be an embroidery loop, and the backing material 48
may be secured to the positioning apparatus using various
mechanical fasteners. When employed, the positioning apparatus
facilitates a consistent placement of the backing material 48
relative to the upper section of the mold 32. The backing material
48 may also be waterproof or water resistant. The positioning
apparatus may attach to the upper section of the mold 32 by
conventional fastening means, including mechanical fasteners,
mechanical positioning devices, magnets and/or adhesives. When the
positioning apparatus, including the attached backing material 48,
is properly attached to the upper section of the mold 32, the
backing material 48 is disposed on an underside of the upper
section of the mold 32 when the upper section of the mold 32 is
properly placed on the lower section of the mold 36. An electronic
identification device, which may be a Radio Frequency
Identification (RFID) device, may be attached to the backing
material 48 and used to verify that the correct insert 40 is being
used for the manufacturing of the correct customized pad for the
correct player.
When the mold upper section 32 is properly placed on top of the
mold lower section 36, a vent stem, configured as a threaded male
member, may allow gasses to escape the internal cavity 44. The vent
stem may be selectively opened to allow various flow rates when the
threaded vent is opened. In some embodiments, the vent stem is
placed into a receptacle in the upper mold section 32. Such a
placement ensures the correct location of the threaded vent
relative to the backing material. The vent stem may also be secured
to the backing material 48. When forming certain customized pads,
for example jaw pads, crown pads and rear pads, the vent is left in
place when the customized pad is completed, and serves to aid in
the attachment of the customized pad to the helmet shell. When
forming other customized pads, for example occipital, front and
side pads, all or a portion of the vent is removed from the
customized pad when the customized pad is completed.
In some embodiments, the vent comprises a channel formed in one or
more of the upper mold section 32 and the backing material 48, and
gasses are selectively allowed to pass from the internal cavity 44
to the exterior of the top mold section via the channel. In a
further embodiment, a grommet formed in the upper mold section 32
frictionally secures, and properly aligns, the vent stem relative
to the upper mold section 32, internal cavity 44 and/or the backing
material 48.
In some embodiments, a pre-formed insert, or a high-ratio internal
insert, may be attached to the upper and/or lower mold sections 32,
36. The pre-formed internal insert may have a particular ratio of
isocyanate to resin, and may have a relatively high ratio of
isocyanate to resin relative to the urethane cast material used to
form the customized pad. In some embodiments, a plug in the
high-ratio internal insert mates with a grommet in the upper mold
section 32 to thereby secure the high-ratio internal insert in
place during the molding process. The urethane casting material
may, wholly or partially, surround the high-ratio internal insert
during the molding process such that the high-ratio internal insert
becomes a portion of the completed customized pad. In some
embodiments, a high-ratio internal insert may be used in the
casting of a customized front pad, occipital pad and jaw pad.
A forming element, which may be formed from silicone, may be placed
into the mold cavity 44 during molding. The forming element may be
freely placed into the mold cavity 44, or may be affixed to one or
more of the upper or lower mold sections 32, 36, high-ratio
internal insert or insert 40, and may serve to create desired
shapes, forms, tolerances and/or characteristics of the final
customized pad. In some embodiments, the forming element creates a
particular radius, or radii, on the customized pad, and the forming
element may further be employed when forming a customized front pad
and a customized occipital pad.
At least one badge which may include indicia such as a player's
name, jersey number and/or signature, and/or a name, slogan or
images of an entity such as a company, may be affixed to one of the
completed customized pads. In particular, a player identification
badge 41, as exemplarily shown in FIG. 1F, may be disposed on a
customized rear pad while a product identification badge,
identifying the helmet model and/or manufacturer, may be placed on
a customized crown pad. The identification badge 41 may also
include a reproduction of the player's actual signature 43. In
addition to enhancing aesthetic appeal and product desirability,
the identification badge 41 is useful in helping a player quickly
ascertain his or her helmet from among a group of
similarly-appearing helmets. A spacing member, which may be a
badge, may be secured to an insert 40 via adhesives or another
mechanical attachment method to conform the shape of the finalized
customized pad to accommodate the attachment of the identification
badge and the product identification badge to the corresponding
customized pads and ensure a proper fit within the customized
helmet.
A covering material 52 is heated for use in the casting process.
The covering material 52 may include Ethylene-Vinyl Acetate (EVA)
and/or may include expanded vinyl and Lycra (elastic polyurethane
fabric) layers. The covering material 52 may form a complete or
partial moisture and/or gas barrier. In some embodiments, the
covering material 52 includes EVA in the form of a foam. Further,
the EVA in the covering material 52 may represent closed cell foam
and may thereby form the moisture barrier.
The covering material 52 may be heated in an oven in isolation, may
be heated in the oven while attached to a covering material
positioning apparatus, or may be heated in the over while attached
to a portion of the lower mold section 36. The covering material
positioning apparatus facilitates a consistent placement of the
covering material 52 relative to the lower section of the mold 36.
Upon the covering material 52 reaching a pre-set temperature, or a
pre-set temperature range, the covering material 52 (optionally via
the covering material positioning apparatus and/or a portion of the
lower mold section 36) is attached to the lower section of the mold
36 by conventional fastening methods, including mechanical
fasteners, mechanical positioning devices, magnets and/or
adhesives. The pre-set temperature, or temperature range, may be a
temperature, or temperature range, appropriate for covering
material vacuum forming, such that the covering material will
deform, or respond to, the vacuum-forming by a particular degree to
adequately form to the insert 40 and lower mold section 36. When
the covering material 52 is properly attached to the lower section
of the mold 36, the covering material 52 is disposed over the
insert 40, such that the insert 40 is disposed substantially
between the covering material 52 and the lower section of the mold
36 within the internal cavity 44.
When the covering material 52 is properly attached to the lower
section of the mold 36 and the covering material 52 is thus
properly disposed over the insert 40 as described, a vacuum
apparatus is operated and creates a partial or complete vacuum
within the internal cavity 44 and vacuum-forms the covering
material 52 to one or more contours of the insert 40 and/or the
lower mold section 36. The vacuum apparatus may be in fluid
communication with the internal cavity 44 through a vacuum aperture
formed in the lower section 36 of the mold, and the vacuum
apparatus may create the partial or complete vacuum within the
internal cavity 44 by negatively pressurizing the internal cavity
44 relative to the exterior of the mold 28 via the vacuum
aperture.
In some embodiments, the covering material 52 is vacuum-formed to
an upper insert surface 50. In this process, the covering material
52 may form to, and adopt the shapes and contours of, the upper
insert surface 50. A weight of the urethane casting material may be
checked for accuracy at this stage.
After the covering material 52 has been vacuum-formed to a surface
of the insert 40, or the upper insert surface 50, the covering
material 52 may form a substantially concave surface within the
lower section of the mold 36. Liquid, solid or semi-solid casting
material, which may also be called urethane and/or padding
material, is then poured into the substantially concave surface
formed in the covering material 52. This process can be termed
`casting.`
The casting material includes isocyanate and resin combined at a
particular ratio. As described above, the ratio of isocyanate and
resin may be determined for the customized pad being created. The
ratio may be determined for a particular type of pad, such as a
front pad or a jaw pad, and/or may be determined for a particular
player based on one or more of player preferences, player head
topographical features, player history, player skill level and
player position.
The upper and lower mold sections 32, 36 are then brought
substantially or wholly together, forming the cavity 44, and the
poured casting material is allowed to cool, cure, solidify, and
take the form of portions of the vacuum-formed covering material
52. In particular, a lower portion of the casting material, or
urethane, may take the form of the vacuum-formed covering material
52, which had previously been vacuum-formed to the upper insert
surface 50. Thus, contours and shapes of the upper insert surface
50 and lower mold section 36 are transferred to the vacuum-formed
covering material 52 and then to the poured casting material.
Further, upper and lateral portions of the casting material may
take the form of a portion of the upper mold section 32,
transferred to the casting material via the backing material 48.
After the poured casting material cools and solidifies, the
now-solidified casting material reflects the shapes and contours of
the vacuum-formed covering material 52 and the upper insert surface
50, as well as the upper and lower sections of the mold 32, 36.
Specifically, a lower surface of the solidified casting material,
or an inner surface of the solidified casting material or
customized pad, may reflect the shapes and contours of the
vacuum-formed covering material 52 and the upper insert surface
50.
After the casting material is cast into the vacuum-formed covering
material 52, pressure may be released from the mold cavity 44. This
may be accomplished by puncturing a seal in the threaded vent,
puncturing the backing material 48, opening a venting element built
into the upper or lower mold sections 32, 36 or partially
separating the upper and lower mold sections 32, 36.
Following the cooling and/or solidification of the casting
material, the customized pad is extricated, or de-molded, from the
now-separated upper and lower mold sections 32, 36. A sealant
material may then be applied to one or more surfaces of the
customized pad. In some embodiments, the sealant material is lycra
(elastic polyurethane fiber), or elastane. In some embodiments, the
sealant material is laminated on, or over, one or more surfaces of
the customized pad. In some embodiments, edges of the customized
pad are sealed with a silicone ring. In some embodiments, edges of
the customized pad are molded with silicone, a sprayed or painted
rubberized material or waterproof tape.
If excess, or undesirable, casting material is present on the
de-molded customized pad, the excess casting material may be
removed by die cutting, or other manual cutting or removal methods.
The dies may include two-dimensional dies and/or three-dimensional
dies. Once separated from the excess casting material, the
customized pad may be checked for various properties, including
density, compression deflection, size, weight, shape, consistency
and color, among other possible properties. In some embodiments, in
addition to or instead of individualized customized pad testing,
test samples are cast and tested at various points to ensure the
consistency and quality of the casting material. Acceptable ranges
or threshold figures may be determined for each variable for which
the customized pad, or test sample, is tested. If a given
customized pad or test sample does not meet an acceptable range or
threshold value for one or more properties, the customized is
re-cast and again checked for the one or more properties. If the
given customized pad meets the acceptable range or threshold value
for the one or more properties, the customized pad is suitable for
use in a customized helmet manufactured using acquired customized
helmet data.
After one or more customized helmet pads 54 are formed by the
above-described process, the one or more customized helmet pads 54
are then attached directly or indirectly to the interior surface of
a helmet shell for use by the player. An example of a customized
internal padding assembly 4 manufactured using the above-described
methods and systems is exemplarily illustrated in FIG. 4A. Further,
turning to FIG. 1B, the customized helmet 2 may also include a
removable external badge 47, adding to the aesthetic appeal and
desirability of the customized helmet. The external badge 47 may
include a range of indicia, images and text including, but not
limited to, a signature of the player.
Fully Bespoke Helmet and System
In the fully bespoke helmet embodiment, the disclosed system and
methods include a number of processes and sub-processes that are
used to acquire and process data concerning the player's unique
anatomical features and then use the processed data to manufacture
a bespoke protective sports helmet where the helmet shell and the
internal padding assembly are both purposely designed, configured
and manufactured to match the anatomical features of the player's
head. The internal padding assembly is purposely designed,
configured and manufactured in the manner explained in the
foregoing paragraphs of the Bespoke Helmet and System section. The
fully bespoke helmet shell is designed based upon (i) the helmet
and hood scans discussed in the foregoing paragraphs of the Bespoke
Helmet and System section, and (ii) a combination of the player's
playing style (including his/her tackling technique), the player's
impact history, the player's skill level, the player's position(s)
(e.g., quarterback, wide receiver, offensive line, linebacker,
etc.), and the extent, if any, of the player's prior injuries.
With these considerations in mind, the fully bespoke helmet shell
can designed to provide increased protection in a particular
region(s) of the shell. This increased protection can be
accomplished by: increasing the thickness of the desired shell
region, adjusting the material properties of the desired shell
region (e.g., increasing the stiffness of the rear region of the
shell), or changing the configuration of the desired shell region
including the shell corrugations in that region (e.g., increasing
the dimensions of the corrugation in the rear shell region).
Partially Bespoke Helmet and System
Embodiments of the present disclosure also include processes and
sub-processes used to acquire and process data concerning the
player's unique anatomical features and subsequently use the
processed data to design, select and optimize a padding assembly
configured to substantially correspond to anatomical features of
the player's head. In some embodiments, the internal padding
assembly of a partially-customized helmet 1000, or a
custom-selected internal padding assembly 1002, includes an
arrangement of custom-selected pads 1004 selected from a large
number of pre-manufactured pads. FIGS. 6A-6D illustrate a
partially-customized helmet 1000, a custom-selected internal
padding assembly 1002 and custom-selected pads 1004.
As described in the above-section detailing acquisition of the
player's anatomical features data, a process for creating the
partially-customized helmet 1000 similarly includes gathering
dimensional, topographical and preference data from the player. In
particular, similar to the processes described above, the process
for creating the partially-customized helmet 1000 may include i)
placing the scanning hood 10 on, or over, the head H of the player
P, ii) verifying that the scanning hood 10 is appropriately
positioned and oriented on the player's head H, iii) selecting a
scanning helmet 15 shell size, iv) placing the scanning helmet 15
over the player's head H while the player P is wearing the scanning
hood 10, v) determining a preferred helmet wearing position, vi)
obtaining a helmet scan using a scanning apparatus 22, vii)
removing the scanning helmet 15 from the player's head H and viii)
obtaining a hood scan using a scanning apparatus 22. However, it is
to be understood that the process for creating the
partially-customized helmet 1000 may include any and all steps,
techniques, technologies, methods and devices, used in any order or
combination, from the section detailing acquisition of the player's
anatomical features data.
Further, the process for creating the partially-customized helmet
1000 may include all steps, techniques, technologies, templates,
methods, and devices as described in the section detailing
acquisition of the player's anatomical features data. In
particular, the process may include ix) confirming adequate helmet
scan quality, x) aligning the helmet scan within three dimensional
software according to the helmet shell template, xi) confirming
adequate hood scan quality, xii) aligning the hood scan relative to
the aligned helmet scan or other reference points, xiii)
verification of MCS satisfaction based on known measurements of a
given helmet shell size, xiv) creating a dimensional inset in the
aligned and MCS-verified hood scan, xv) accounting for player
preferences, history, position, skill level or other factors in the
aligned, inset, and MCS-verified hood scan and modifying the hood
scan accordingly and xvi) comparing the aligned, inset,
MCS-verified hood scan with one or more partially-customized pad
selection layers in the helmet shell template.
The partially-customized pad selection layer may include
three-dimensional models of a range of custom-selected pads 1004.
The custom-selected pads 1004 are pre-formed, and include a wide
range of physical characteristics. For example, the custom-selected
pads 1004 include a variety of lengths, widths, heights,
compression deflections, contours, concavities, angles, radii,
attachment systems, colors and materials, as well as a range of
isocyanate to resin ratios. As will be understood by one skilled in
the art, upon a comparison of the aligned, inset, MCS-verified hood
scan data with the one or more partially-customized pad selection
layers in the helmet shell template, a custom-selected internal
padding assembly 1002 may be selected for that player's
partially-customized helmet 1000 that includes an arrangement of
custom-selected pads 1004. The custom-selected pads 1004 may be
selected based upon the aligned, inset and MCS-verified hood scan
data, a dimensional fit or connection between a particular
custom-selected pad 1004 and a helmet shell, and/or a dimensional
fit or connection between custom-selected pads 1004.
The custom-selected internal padding assembly 1002, as exemplarily
shown in FIGS. 6A-6C, comprises individual custom-selected pads
1004 for use in the partially-customized helmet 1000. For example,
the custom-selected pads 1004 include a custom-selected front pad
1080, a custom-selected crown pad 1081, a custom-selected rear pad
1082, a custom-selected left side pad 1083, a custom-selected right
side pad 1084, a custom-selected occipital pad 1085, a
custom-selected left jaw pad 1086 and a custom-selected right jaw
pad 1087
Further, although the use of a partially-customized pad selection
layer within a helmet shell template is described, it is to be
understood that any method of forming a partially-customized helmet
1000 using custom-selected pads 1004 selected from a large number
of pre-manufactured pads based upon gathered player physical data
is within the scope of this disclosure.
On-field results of monitored head impact exposures (HIE) collected
by the proprietary technologies owned by the assignee of the
present Application can be used to inform certain design parameters
of the bespoke helmet discussed above. The monitored HIE results
were obtained by the assignee's advanced wearable monitoring
systems, that features an arrangement of impact monitoring sensors,
disclosed in U.S. patent application Ser. No. 13/603,319 and U.S.
Pat. Nos. 6,826,509, 7,526,389, 8,797,165 and 8,548,768, each of
which including the content thereof are hereby incorporated by
reference. For instance, a football player's skill or age level and
playing position may, when compared to a larger database of similar
players, indicate certain preferred helmet design characteristics.
These characteristics may provide benefit to players based upon
expected HIE levels at differing skill/age levels and/or on-field
playing positions or groups of playing positions. Hypothetically, a
college football quarterback may expect an elevated HIE metric of
high-intensity impacts directed to the back of the head. The
bespoke helmet, including the internal padding assembly, can be
adjusted to provide greater protection levels accordingly.
Examples of using the HIE results to inform design parameters
include using the impact data collected and stored in a database to
create a position and/or skill level specific helmet that is
designed based upon a generic data set based on skill level and
position, but not influenced by a specific player's impact results
and data. Another example of utilizing the HIE results includes
using the HIE data collected from a specific player in combination
with the broader data that has been collected and stored in the
repository to create a fully personalized helmet. Another example
of utilizing the HIE results involves installing sensor
instrumentation in a player's helmet to enable further
customization based on additional data that is collected after a
pre-set amount of time or play. This instrumentation is included in
the personalized helmet to further inform the data set and how to
alter the inserts to provide a greater bespoke fit. These examples
and the usage of HIE results applies to all three bespoke
embodiments discussed above--the bespoke helmet and system, the
fully bespoke helmet and system, and the partially bespoke helmet
and system.
As is known in the data processing and communications arts, a
general-purpose computer typically comprises a central processor or
other processing device, an internal communication bus, various
types of memory or storage media (RAM, ROM, EEPROM, cache memory,
disk drives etc.) for code and data storage, and one or more
network interface cards or ports for communication purposes. The
software functionalities involve programming, including executable
code as well as associated stored data. The software code is
executable by the general-purpose computer. In operation, the code
is stored within the general-purpose computer platform. At other
times, however, the software may be stored at other locations
and/or transported for loading into the appropriate general-purpose
computer system.
A server, for example, includes a data communication interface for
packet data communication. The server also includes a central
processing unit (CPU), in the form of one or more processors, for
executing program instructions. The server platform typically
includes an internal communication bus, program storage and data
storage for various data files to be processed and/or communicated
by the server, although the server often receives programming and
data via network communications. The hardware elements, operating
systems and programming languages of such servers are conventional
in nature, and it is presumed that those skilled in the art are
adequately familiar therewith. The server functions may be
implemented in a distributed fashion on a number of similar
platforms, to distribute the processing load.
Hence, aspects of the disclosed methods and systems outlined above
may be embodied in programming. Program aspects of the technology
may be thought of as "products" or "articles of manufacture"
typically in the form of executable code and/or associated data
that is carried on or embodied in a type of machine readable
medium. "Storage" type media include any or all of the tangible
memory of the computers, processors or the like, or associated
modules thereof, such as various semiconductor memories, tape
drives, disk drives and the like, which may provide non-transitory
storage at any time for the software programming. All or portions
of the software may at times be communicated through the Internet
or various other telecommunication networks. Thus, another type of
media that may bear the software elements includes optical,
electrical and electromagnetic waves, such as used across physical
interfaces between local devices, through wired and optical
landline networks and over various air-links. The physical elements
that carry such waves, such as wired or wireless links, optical
links or the like, also may be considered as media bearing the
software. As used herein, unless restricted to non-transitory,
tangible "storage" media, terms such as computer or machine
"readable medium" refer to any medium that participates in
providing instructions to a processor for execution.
A machine readable medium may take many forms, including but not
limited to, a tangible storage medium, a carrier wave medium or
physical transmission medium. Non-volatile storage media include,
for example, optical or magnetic disks, such as any of the storage
devices in any computer(s) or the like, such as may be used to
implement the disclosed methods and systems. Volatile storage media
include dynamic memory, such as main memory of such a computer
platform. Tangible transmission media include coaxial cables,
copper wire and fiber optics, including the wires that comprise a
bus within a computer system. Carrier-wave transmission media can
take the form of electric or electromagnetic signals, or acoustic
or light waves such as those generated during radio frequency (RF)
and infrared (IR) data communications. Common forms of
computer-readable media therefore include for example: a floppy
disk, a flexible disk, hard disk, magnetic tape, any other magnetic
medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch
cards, paper tape, any other physical storage medium with patterns
of holes, a RAM, a PROM and EPROM, a FLASH-EPROM, any other memory
chip or cartridge, a carrier wave transporting data or
instructions, cables or links transporting such a carrier wave, or
any other medium from which a computer can read programming code
and/or data. Many of these forms of computer readable media may be
involved in carrying one or more sequences of one or more
instructions to a processor for execution.
While the foregoing has described what are considered to be the
best mode and/or other examples, it is understood that various
modifications may be made therein and that the subject matter
disclosed herein may be implemented in various forms and examples,
and that the teachings may be applied in numerous applications,
only some of which have been described herein. It is intended by
the following claims to claim any and all applications,
modifications and variations that fall within the true scope of the
present teachings.
Other implementations are also contemplated.
* * * * *